Coolant delivery via an independent cooling circuit

ABSTRACT

An embodiment of an independent cooling circuit for selectively delivering cooling fluid to a component of a gas turbine system includes: at least one coolant feed channel fluidly coupled to a supply of cooling fluid; and an interconnected circuit of cooling channels, including: an interconnected circuit of cooling channels embedded within an exterior wall of the component; an impingement plate; and a plurality of feed tubes connecting the impingement plate to the exterior wall of the component and fluidly coupling a supply of cooling fluid to the interconnected circuit of cooling channels; wherein the cooling fluid flows through the plurality of feed tubes into the interconnected circuit of cooling channels only in response to a formation of a breach in the exterior wall of the component that exposes at least one of the cooling channels.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with government support under contract DE-FE0031611 awarded by the United States Department of Energy. The government has certain rights.

BACKGROUND

The disclosure relates generally to turbine systems, and more particularly, to the delivery of cooling fluid to a component of a gas turbine system via an independent cooling circuit.

Gas turbine systems are one example of turbomachines widely utilized in fields such as power generation. A conventional gas turbine system generally includes a compressor section, a combustor section, and a turbine section. During operation of a gas turbine system, various components in the system, such as turbine blades, nozzle airfoils, and shroud segments are subjected to high temperature gas flows, which can cause the components to fail. Since higher temperature gas flows generally result in increased performance, efficiency, and power output of a gas turbine system, it is advantageous to cool the components that are subjected to high temperature gas flows to allow the gas turbine system to operate at increased temperatures and to extend the lifetime of the components of a gas turbine system.

Cooling (e.g., convection cooling, impingement cooling, etc.) is often provided by directing a flow of a cooling fluid through internal passages formed in the components of the gas turbine system. In many cases, the cooling fluid is provided by bleeding off a portion of the air discharged by the compressor section of the gas turbine system.

A thermal barrier coating (TBC) is often applied to the components of a gas turbine system to provide a protective heat shield, prevent damage due to high temperatures, and extend component life by reducing oxidation and thermal fatigue. Spallation of the TBC is a common issue in gas turbine systems. When the TBC spalls, portions of the TBC may crack and break off a component, exposing underlying surfaces to high temperatures and damage (e.g., a wall breach).

SUMMARY

An aspect of the disclosure is directed to an independent cooling circuit for selectively delivering a flow of cooling fluid to a component of a gas turbine system, including: an interconnected circuit of cooling channels embedded within an exterior wall of the component; an impingement plate; and a plurality of feed tubes connecting the impingement plate to the exterior wall of the component and fluidly coupling a supply of cooling fluid to the interconnected circuit of cooling channels; wherein the cooling fluid flows through the plurality of feed tubes into the interconnected circuit of cooling channels only in response to a formation of a breach in the exterior wall of the component that exposes at least one of the cooling channels.

Another aspect of the disclosure is directed to a cooling system, including: a component of a gas turbine system; and an independent cooling circuit for selectively delivering cooling fluid to a component of a gas turbine system, including: an interconnected circuit of cooling channels embedded within an exterior wall of the component; an impingement plate; and a plurality of feed tubes connecting the impingement plate to the exterior wall of the component and fluidly coupling a supply of cooling fluid to the interconnected circuit of cooling channels; wherein the cooling fluid flows through the plurality of feed tubes into the interconnected circuit of cooling channels only in response to a formation of a breach in the exterior wall of the component that exposes at least one of the cooling channels.

A further aspect of the disclosure is directed to a method for reducing spallation-related damage to a component of a gas turbine system, including: embedding an interconnected circuit of cooling channels within a section of an external wall of the component; and directing a flow of cooling fluid into the interconnected circuit of cooling channels only in response to a wall breach exposing a portion of the interconnected circuit of cooling channels.

The illustrative aspects of the present disclosure solve the problems herein described and/or other problems not discussed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of this disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure.

FIG. 1 depicts a schematic diagram of a gas turbine system according to embodiments.

FIG. 2 depicts a side view of a portion of a turbine section of a gas turbine system according to embodiments.

FIG. 3 depicts a perspective view of a turbine blade according to embodiments.

FIGS. 4A and 4B depict an example of impingement cooling prior to and after formation of a wall breach, respectively.

FIG. 5 depicts an independent cooling circuit in a component of a gas turbine system looking outward from the interior of the component according to embodiments.

FIG. 6 depicts the independent cooling circuit of FIG. 5 looking inward from the exterior of the component according to embodiments.

FIG. 7 depicts the independent cooling circuit of FIG. 6 with a portion of the exterior wall removed to show the interconnected circuit of cooling channels according to embodiments.

FIG. 8 depicts another view of the independent cooling circuit of FIG. 5 with a portion of the exterior wall of the component removed according to embodiments.

FIG. 9 depicts a cross-sectional view of the independent cooling circuit of FIG. 5 according to embodiments.

FIG. 10 depicts the operation of the independent cooling circuit of FIG. 5 after a partial or full exterior wall breach according to embodiments.

FIG. 11 depicts an independent cooling circuit in a component of a gas turbine system according to additional embodiments.

FIG. 12 depicts the independent cooling circuit of FIG. 11 with a portion of the exterior wall of the component removed according to additional embodiments.

FIG. 13 depicts another view of the independent cooling circuit of FIG. 11 according to additional embodiments.

FIG. 14 depicts an independent cooling circuit in a component of a gas turbine system according to further embodiments.

FIG. 15 depicts another view of the independent cooling circuit of FIG. 14 according to further embodiments.

FIG. 16 depicts a block diagram of an additive manufacturing process including a non-transitory computer readable storage medium storing code representative of an object according to embodiments.

FIGS. 17 and 18 depict an additively manufactured wall coupon for a component of a gas turbine system according to embodiments.

FIGS. 19 and 20 depict an additively manufactured wall coupon with powder removal openings according to embodiments.

It is noted that the drawings of the disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the disclosure, and therefore should not be considered as limiting the scope of the disclosure. In the drawings, like numbering represents like elements between the drawings.

DETAILED DESCRIPTION

Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims.

As an initial matter, in order to clearly describe the current disclosure, it will become necessary to select certain terminology when referring to and describing relevant machine components within the scope of this disclosure. When doing this, if possible, common industry terminology will be used and employed in a manner consistent with its accepted meaning. Unless otherwise stated, such terminology should be given a broad interpretation consistent with the context of the present application and the scope of the appended claims. Those of ordinary skill in the art will appreciate that often a particular component may be referred to using several different or overlapping terms. What may be described herein as being a single part may include and be referenced in another context as consisting of multiple components. Alternatively, what may be described herein as including multiple components may be referred to elsewhere as a single part.

In addition, several descriptive terms may be used regularly herein, and it should prove helpful to define these terms at the onset of this section. These terms and their definitions, unless stated otherwise, are as follows. As used herein, “downstream” and “upstream” are terms that indicate a direction relative to the flow of a fluid, such as the working fluid through the turbine engine or, for example, the flow of air through the combustor or coolant through one of the turbine's component systems. The term “downstream” corresponds to the direction of flow of the fluid, and the term “upstream” refers to the direction opposite to the flow. The terms “forward” and “aft,” without any further specificity, refer to directions, with “forward” referring to the front or compressor end of the engine, and “aft” referring to the rearward or turbine end of the engine. Additionally, the terms “leading” and “trailing” may be used and/or understood as being similar in description as the terms “forward” and “aft,” respectively. It is often required to describe parts that are at differing radial, axial and/or circumferential positions. The “A” axis represents an axial orientation. As used herein, the terms “axial” and/or “axially” refer to the relative position/direction of objects along axis A, which is substantially parallel with the axis of rotation of the gas turbine system (in particular, the rotor section). As further used herein, the terms “radial” and/or “radially” refer to the relative position/direction of objects along a direction “R” (see, FIG. 1), which is substantially perpendicular with axis A and intersects axis A at only one location. Finally, the term “circumferential” refers to movement or position around axis A (e.g., direction “C”).

In various embodiments, components described as being “fluidly coupled” to or “in fluid communication” with one another can be joined along one or more interfaces. In some embodiments, these interfaces can include junctions between distinct components, and in other cases, these interfaces can include a solidly and/or integrally formed interconnection. That is, in some cases, components that are “coupled” to one another can be simultaneously formed to define a single continuous member. However, in other embodiments, these coupled components can be formed as separate members and be subsequently joined through known processes (e.g., fastening, ultrasonic welding, bonding).

When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

FIG. 1 depicts a schematic diagram of a gas turbine system 10 according to various embodiments. As shown, the gas turbine system 10 includes a compressor section 12 for compressing an incoming flow of air 14 and for delivering a flow of compressed air 16 to a combustor section 18. The combustor section 18 mixes the flow of compressed air 16 with a pressurized supply of fuel 20 and ignites the mixture to create a flow of combustion gases 22. Although only a single combustor section 18 is shown, the gas turbine system 10 may include any number of combustor sections 18. The flow of combustion gases 22 is in turn delivered to a turbine section 24. The flow of combustion gases 22 drives the turbine section 24 to produce mechanical work. The mechanical work produced in the turbine section 24 drives the compressor section 12 via a shaft 26 and may be used to drive an external load 28, such as an electrical generator and/or the like.

FIG. 2 depicts a side view of a portion of a turbine section 24 of a gas turbine system, including at least one stage 30 of turbine blades 32 (one shown) and at least one stage 34 of nozzles 36 (one shown) positioned within a casing 38 of the turbine section 24. Each stage 30 of turbine blades 32 includes a plurality of turbine blades 32 that are coupled to and positioned circumferentially about the rotor 26, and which are driven by the combustion gases 22. Each stage 34 of nozzles 36 includes a plurality of nozzles 36 that are coupled to and positioned circumferentially about the casing 38 of the turbine section 24. In the embodiment shown in FIG. 2, each nozzle 36 includes an airfoil 40 positioned between an outer platform 42 and an inner platform 44.

Similar to the nozzles 36, each turbine blade 32 of the turbine section 24 includes an airfoil 46 extending radially from the rotor 26. Each airfoil 46 includes a tip portion 48 and a platform 50 positioned opposite the tip portion 48.

The turbine blades 32 and the nozzles 36 may be positioned axially adjacent to one another within the casing 38. In FIG. 2, for example, the nozzles 36 are shown positioned axially adjacent and downstream of the turbine blades 32. The turbine section 24 may include a plurality of stages 30 of turbine blades 32 and a plurality of stages 34 of nozzles 36, positioned axially throughout the casing 38.

The turbine section 24 of the gas turbine system 10 may include a plurality of stages 52 of shrouds 54 (one stage shown in FIG. 2) positioned axially throughout the casing 38. In FIG. 2, for example, the stage 52 of shrouds 54 is shown positioned radially adjacent to and substantially surrounding or encircling the stage 30 of turbine blades 32. The stage 52 of shrouds 54 may also be positioned axially adjacent and/or upstream of the stage 34 of nozzles 36. Further, the stage 52 of shrouds 54 may be positioned between two adjacent stages 34 of nozzles 36 located on opposing sides of a stage 30 of turbine blades 32. The stage 52 of shrouds 54 may be coupled about the casing 38 of the turbine section 24 using a set of extensions 56, each including an opening 58 configured to receive a corresponding section of a shroud 54.

Turning to FIG. 3, a perspective view of a turbine blade 32 is shown. The turbine blade 32 includes a shank 60, a platform 50 located radially above the platform 50, and an airfoil 46 coupled to and extending radially outward from the platform 50. The airfoil 46 includes a pressure side 62, an opposed suction side 64, and a tip portion 48. The airfoil 46 further includes a leading edge 68 between the pressure side 62 and the suction side 64, as well as a trailing edge 70 between the pressure side 62 and suction side 64 on a side opposing the leading edge 68.

Many components of a gas turbine system (e.g., turbine blades, nozzles, shrouds, etc.) may be cooled during operation by directing a fixed supply of a cooling fluid through internal passages formed in the components. In many cases, the cooling fluid is provided by bleeding off a fixed supply of air discharged by the compressor section of the gas turbine system.

Many different internal cooling methodologies may be used to cool a component of a gas turbine system including, for example, convection cooling, film cooling, and impingement cooling. Convection cooling works by passing a flow of a cooling fluid through passages internal to the component. Heat is transferred by conduction through the component, and then to the cooling fluid flowing through the component. With film cooling, cooling fluid is discharged to an external surface of the component via small holes formed through an exterior wall of the component. The cooling fluid provides a thin, cool, insulating blanket along the external surface of the component. Impingement cooling, a variation of convection cooling, works by directing a higher velocity flow of a cooling fluid against an interior surface of the component. This allows more heat to be transferred by convection than regular convection cooling. Impingement cooling is often used in regions of the component exposed to high heat loads (e.g., the leading edge of a turbine blade).

If a breach forms (e.g., as a consequence of TBC spallation or other damage) in a portion of a component of a gas turbine system and exposes any internal cooling passages, some of the fixed supply of cooling fluid may flow from the exposed internal cooling passages and out of the component through the breach. This reduces the remaining amount of the fixed supply of cooling fluid available to the component, decreasing cooling effectiveness, and potentially resulting in component failure. An example of such a wall breach is depicted in FIGS. 4A and 4B.

FIG. 4A depicts an example of impingement cooling in a component 80 of a gas turbine system (e.g., gas turbine system 10, FIG. 1). As shown, a supply of a cooling fluid 82 is directed against an inner surface 84 of an exterior wall 86 of the component 80 though a plurality of openings 88 formed in an impingement plate 90. The outer surface 92 of the exterior wall 86 of the component 80 is exposed to a hot gas flow 94. FIG. 4B depicts the component 80 with a breach 96 extending through the exterior wall 86. As shown, a portion of the cooling fluid 82 escapes through the exterior wall 86 of the component 80 through the breach 96, reducing available cooling to the component 80 causing damage to spread and potentially resulting in component failure.

According to embodiments, an independent cooling circuit is provided to deliver an additional, independent supply of cooling fluid to a component of a gas turbine system in response to a partial or full wall breach. The component may include, for example, a turbine blade, nozzle airfoil, shroud segment, combustion liner, or other component that may require cooling during operation of the gas turbine system. An interconnected circuit of cooling channels is embedded within an exterior wall of the component. A plurality of coolant feed channels are provided within the component (e.g., within/on an impingement plate or insert, within/on an interior wall, and/or the like). A plurality of feed tubes fluidly couple the coolant feed channels and the interconnected circuit of cooling channels embedded within the exterior wall of the component. During normal operation (e.g., the absence of a partial or full breach in the exterior wall of the component), cooling fluid does not flow through the independent cooling circuit, since there is no outlet for the cooling fluid. However, when a partial or full wall breach occurs and exposes at least a portion of the interconnected circuit of cooling channels embedded within the exterior wall of the component, a flow path is created, which allows a supply of cooling fluid to flow through the coolant feed channels, feed tubes, and interconnected circuit of cooling channels toward the affected area. The cooling provided by this additional, independent flow of cooling fluid may extend the life of the component (e.g., reduce/prevent additional spallation in the area of the breach) after surface damage has occurred without affecting the baseline cooling effectiveness (e.g., impingement cooling) within the component.

A first embodiment of an independent cooling circuit 100 for a component 102 of a gas turbine system 10 (FIG. 1) according to embodiments is illustrated in FIGS. 5-10. The component 102 may comprise any component of a gas turbine system 10 that may require cooling including, without limitation, a turbine blade, nozzle airfoil, shroud segment, combustion liner, etc. In this example, an impingement cooling arrangement 104 is used to cool an exterior wall 106 of the component 102. For example, to provide impingement cooling, a supply of cooling fluid 108 may be directed into an internal cavity 110 of the component 102 during operation of the gas turbine system 10. The supply of cooling fluid 108 may be provided, for example, by bleeding off a supply of air discharged by the compressor section 12 (FIG. 1) of the gas turbine system 10. The cooling fluid 108 flows from the internal cavity 110, through a plurality of impingement holes 112 formed in an impingement plate 114, into an impingement cavity 118, and against an interior surface 116 of the exterior wall 106 of the component 102. After impinging against the interior surface 116 of the exterior wall 106, the cooling fluid 108 may be directed from the impingement cavity 118 to one or more interior/exterior areas of the component 102 (e.g., for film cooling). Although described in this and other embodiments in conjunction with impingement cooling, the independent cooling circuit 100 may be used together with other cooling arrangements (e.g., convection cooling, etc.).

The independent cooling circuit 100 depicted in FIGS. 5-10 (referred to concurrently) includes a single pressurized supply of cooling fluid 128, a plurality of coolant feed channels 120 (although not always required depending on application), a plurality of feed tubes 122 connecting the impingement plate 114 to the exterior wall 106, and an interconnected circuit 124 (FIGS. 7-10) of cooling channels 126 embedded within the exterior wall 106 of the component 102. The interconnected circuit 124 of cooling channels 126 is fully enclosed within the exterior wall 106 of the component 102, such that none of the cooling channels 126 extends to or is exposed at the outer surface 132 (e.g., the hot gas surface) of the exterior wall 106. The coolant feed channels 120 may be attached to the impingement plate 114, formed as part of or within the impingement plate 114, or provided in any other suitable manner. According to embodiments, the nominal location of the feed tubes 122 may be midway between the intersections 130 to ensure feed at a breach which is most likely to occur at the intersections 130. In other embodiments, the feed tubes 122 may be located at or near the intersections 130.

Each of the coolant feed channels 120 is fluidly coupled, via a plurality of openings 121 in the impingement plate 114 and a plurality of the feed tubes 122, to the interconnected circuit 124 of cooling channels 126. The coolant feed channels 120 are each fluidly coupled to a pressurized supply of cooling fluid 128 that is independent of the supply of cooling fluid 108 provided to the impingement cooling arrangement 104. The supply of cooling fluid 128 may be provided by bleeding off a supply of air discharged by the compressor section 12 of the gas turbine system 10, or in any other suitable manner (e.g., a source of compressed air provided by a source other than the compressor section 12 of the gas turbine system 10). The interconnected circuit 124 of cooling channels 126 does not include an outlet for the cooling fluid 128. The coolant feed channels 120, if required, may also include individual passages feeding each feed tube 122. In other embodiments, the coolant feed channels 120 may be integral to the exterior wall 106. In embodiments where cooling feed channels 120 are not used, the pre-impingement cooling fluid 108 may be fed through the plurality of feed tubes 122 into the interconnected circuit 124 of cooling channels 126.

In the embodiment shown in FIGS. 5-10, the cooling channels 126 of the interconnected circuit 124 may be embedded within the exterior wall 106 of the component 102 at approximately the same distance from the outer surface 132 of the exterior wall 106 (e.g., in a planar configuration). Further, the feed tubes 122 may extend approximately the same distance into the exterior wall 106 to the cooling channels 126 of the interconnected circuit 124. Multiple intersections 130 may be provided to fluidly interconnect all of the cooling channels 126 of the interconnected circuit 124. The cooling channels 126 may be arranged in a grid-like pattern (e.g., a rectangular grid) within the exterior wall 106 and may extend linearly between the feed tubes 122 and/or between the intersections 130.

In other embodiments, as will be described in greater detail below, the cooling channels 126 (or portions thereof) of the interconnected circuit 124 may be embedded within the exterior wall 106 at different distances from the outer surface 132 of the exterior wall 106. This may require the feed tubes 122 to extend different distances into the exterior wall 106 to the cooling channels 126 of the interconnected circuit 124.

During normal operation (e.g., the absence of a partial or full breach in the exterior wall 106 of the component 102), there is no flow of the cooling fluid 128 through the independent cooling circuit 100, since the interconnected circuit 124 of cooling channels 126 is embedded and fully enclosed within the exterior wall 106 and does not include an outlet for the cooling fluid 128. However, as shown in FIG. 10, in response to a formation of a partial or full wall breach 96 in the exterior wall 106 of the component 102, at least a portion of the cooling channels 126 in the exterior wall 106 of the component 102 may become exposed, providing an outlet for the cooling fluid 128. To this extent, the cooling fluid 128 can now flow thru the cooling channels 126 exposed by the wall breach 96. In particular, the cooling fluid 128 may flow through the coolant feed channels 120, the plurality of feed tubes 122, and the cooling channels 126 of the interconnected circuit 124 toward and out of the cooling channels 126 exposed by the wall breach 96. The cooling fluid 128 ultimately flows out of the exposed cooling channels 126 in the breach 96 to an exterior of the component 102. In general, the flow rate of the cooling fluid 128 increases in the cooling channels 126 closest to the breach 96. The flow of cooling fluid 128 provides additional cooling to the component 102 in the area adjacent the wall breach 96, independently of any cooling provided by the impingement cooling arrangement 104. The additional cooling provided by the cooling fluid 128 may, for example, reduce additional spalling or prevent additional spalling from occurring in the area of the breach 96. This may prevent the breach 96 from increasing in size and may extend the operational life of the component 102.

The independent cooling system 100 includes a plurality of coolant feed channels 120 and a plurality of feed tubes 122. Further, the cooling channels 126 are interconnected by a plurality of intersections 130. Another embodiment of an independent cooling circuit 200, which includes a plurality of feed channels, a plurality of feed tubes, and a plurality of cooling channels interconnected by a plurality of intersections, is illustrated in FIGS. 11-13 (referred to concurrently).

As in the embodiment illustrated in FIGS. 5-10, an impingement cooling system 104 is provided to cool an exterior wall 106 of the component 102. To provide impingement cooling, a supply of cooling fluid 108 is directed into an internal cavity 110 (see, e.g., FIG. 5) of the component 102 during operation of the gas turbine system 10. The cooling fluid 108 flows from the internal cavity 110, through a plurality of impingement holes 112 (e.g., formed in an impingement plate 114), into an impingement cavity 118, and against an interior surface 116 of the exterior wall 106 of the component 102.

The independent cooling circuit 200 may include a plurality of coolant feed channels 120 (see, e.g., FIG. 5) (although not always required depending on application), a plurality of feed tubes 202 connecting the impingement plate 114 to the exterior wall 106, and an interconnected circuit 204 of cooling channels 206 embedded within the exterior wall 106 of the component 102. The interconnected circuit 204 of cooling channels 206 is fully enclosed within the exterior wall 106 of the component 102, such that none of the cooling channels 206 extends to or is exposed at the outer surface 132 of the exterior wall 106 of the component 102. Multiple intersections 208 are provided to fluidly couple all of the cooling channels 206. The interconnected circuit 204 of cooling channels 206 does not include an outlet for cooling fluid 128. The cooling channels 206 may be arranged in a grid-like pattern (e.g., rectangular grid) within the exterior wall 106.

Unlike the cooling channels 126 of the interconnected circuit 124 described above with regard to FIGS. 5-10, which extend linearly between the feed tubes 122 and/or between the intersections 130, some or all of the cooling channels 206 in the interconnected circuit 204 of the independent cooling circuit 200 may have a non-linear configuration (e.g., a zig-zag configuration as shown, a sinusoidal configuration, etc.). As depicted in FIGS. 11-13, for example, the cooling channels 206 may zig-zag within the exterior wall 106 between the feed tubes 202 and/or between the intersections 208. As a result, the distance between the cooling channels 206 and the outer surface 132 of the exterior wall 106 may vary.

During normal operation (e.g., the absence of a partial or full breach 96 (see, e.g., FIG. 10) in the exterior wall 106), there is no flow of cooling fluid 128 through the independent cooling circuit 200, since the interconnected circuit 204 of cooling channels 206 is embedded and fully enclosed within the exterior wall 106 of the component 102 and does not include an outlet for the cooling fluid 128. When a partial or full wall breach 96 occurs in the exterior wall 106, at least a portion of the cooling channels 206 in the exterior wall 106 of the component 102 may become exposed, providing an outlet for the cooling fluid 128. As a result, the cooling fluid 128 can now flow through the coolant feed channels 120 (FIG. 5), a plurality of openings 201 in the impingement plate 114, the plurality of feed tubes 202, and the cooling channels 206 of the interconnected circuit 204, before flowing out of the cooling channels 206 exposed by the wall breach 96. This flow of cooling fluid 128 provides additional cooling to the component 102 in the area adjacent the wall breach 96, independently of any cooling provided by the impingement cooling arrangement 104. In embodiments where cooling feed channels 120 are not used, the pre-impingement cooling fluid 108 may be fed through the plurality of feed tubes 122 into the interconnected circuit 204 of cooling channels 206.

Advantageously, the longer flow path of the cooling fluid 128 due to the non-linear configuration of the interconnected circuit 204 of cooling channels 206 may enhance heat transfer to the cooling fluid 128 and enhance the cooling effectiveness of the independent cooling circuit 200. In addition, portions of the cooling channels 206 located closer to the outer surface 132 of the external wall 106 of the component 102 may become exposed in response to the formation of a shallower/smaller breach 96. As a result, the independent cooling circuit 200 may activate sooner in response to a spallation event than the independent cooling circuit 100, which has a planar configuration. Further, the additional cooling provided by the cooling fluid 128 may, for example, reduce additional spalling or prevent additional spalling from occurring in the area of the breach 96. This may prevent the breach 96 from increasing in size and may extend the operational life of the component 102.

An independent cooling circuit 300 according to a further embodiment is depicted in FIGS. 14 and 15. Again, as in the above-described embodiments, the independent cooling circuit 300 includes a plurality of feed channels, a plurality of feed tubes connecting the impingement plate 114 to the exterior wall 106, and a plurality of cooling channels interconnected by a plurality of intersections.

As in the other embodiments, an impingement cooling system 104 is provided to cool an exterior wall 106 of the component 102. To provide impingement cooling, a supply of cooling fluid 108 is directed into an internal cavity 110 (see, e.g., FIG. 5) of the component 102 during operation of the gas turbine system 10. The cooling fluid 108 flows from the internal cavity 110, through a plurality of impingement holes 112 (e.g., formed in an impingement plate 114), into an impingement cavity 118, and against an interior surface 116 of the exterior wall 106 of the component 102.

The independent cooling circuit 300 includes a plurality of feed tubes 302 connecting the impingement plate 114 to the exterior wall 106 and an interconnected circuit 304 of cooling channels 306, 308. The feed tubes 302 are fluidly coupled to coolant feed channels 120 (FIG. 5) (although not always required depending on application). The cooling channels 306 are arranged in a grid-like pattern (e.g., a rectangular grid) and extend between intersections 310 that are fluidly coupled to the feed tubes 202. The cooling channels 308 extend diagonally between adjacent intersections 310. Intersecting pairs of the cooling channels 308 may be fluidly coupled together at intersections 312. The interconnected circuit 304 of cooling channels 306, 308 does not include an outlet for cooling fluid 128. In embodiments where cooling feed channels 120 are not used, the pre-impingement cooling fluid 108 may be fed through the plurality of feed tubes 122 into the interconnected circuit 304 of cooling channels 306.

Some or all of the cooling channels 306, 308 in the interconnected circuit 304 of the independent cooling circuit 300 may have a non-linear configuration (e.g., a zig-zag configuration as shown, a sinusoidal configuration, etc.). As shown in FIGS. 14 and 15, for example, the cooling channels 306, 308 may zig-zag within the exterior wall 106 between the intersections 310 and 312, respectively. Such a non-linear configuration provides a longer flow path within the exterior wall 106, which may enhance the heat transfer to the cooling fluid 128 and enhance the cooling effectiveness of the independent cooling circuit 300. The use of the diagonally-extending cooling channels 308 may also enhance heat transfer to the cooling fluid 128.

Comparing FIG. 15 to FIG. 8 or 13, it can be seen that the interconnected circuit 304 may also provide a higher density of cooling channels 306, 308 than the interconnected circuits 104, 204, due to the incorporation of the diagonally-extending cooling channels 308. To this extent, the cooling channels 306, 308 in the interconnected circuit 304 may be more likely to be exposed in response to the formation of a smaller wall breach 96. Further, the higher density of cooling channels 306, 308 may enhance heat transfer to the cooling fluid 128 and enhance the cooling effectiveness of the independent cooling circuit 300. In addition, portions of the cooling channels 306, 308 located closer to the outer surface 132 of the external wall 106 of the component 102 may become exposed in response to the formation of a shallower/smaller breach 96, resulting in an earlier activation of the independent cooling circuit 300 (e.g., compared to the independent cooling circuit 100).

During normal operation (e.g., the absence of a partial or full breach 96 (see, e.g., FIG. 10) in the exterior wall 106 of the component 102), there is no flow of cooling fluid 128 through the independent cooling circuit 300, since the interconnected circuit 304 of cooling channels 306, 308 is embedded and fully enclosed within the exterior wall 106 and does not include an outlet for the cooling fluid 128. When a partial or full wall breach 96 occurs in the exterior wall 106, at least a portion of the channels 306 and/or 308 in the exterior wall 106 of the component 102 may become exposed, providing an outlet for the cooling fluid 128. As a result, the cooling fluid 128 can now flow toward (and out of) the exposed cooling channels 306, 308 at the wall breach 96, through the coolant feed channels 120, the plurality of feed tubes 302, and the cooling channels 306, 308 of the interconnected circuit 304.

The flow of cooling fluid 128 via the independent cooling circuit 300 provides additional cooling to the component 102 in the area adjacent the wall breach 96, independently of any cooling provided by the impingement cooling arrangement 104. The additional cooling provided by the cooling fluid 128 may, for example, reduce additional spalling or prevent additional spalling from occurring in the area of the breach 96. This may prevent the breach 96 from increasing in size and may extend the operational life of the component 102.

Various components and features of the independent cooling circuits 100, 200, 300 of the present disclosure may be formed using an additive manufacturing process. Advantageously, additive manufacturing enables the design and production of more customizable and intricate features.

As used herein, additive manufacturing may include any process of producing an object through the successive layering of material rather than the removal of material, which is the case with conventional processes. Additive manufacturing can create complex geometries without the use of any sort of tools, molds or fixtures, and with little or no waste material. Instead of machining components from solid billets of plastic or metal, much of which is cut away and discarded, the only material used in additive manufacturing is what is required to shape the part. Additive manufacturing processes may include but are not limited to: 3D printing, rapid prototyping (RP), direct digital manufacturing (DDM), binder jetting, selective laser melting (SLM) and direct metal laser melting (DMLM). In the current setting, DMLM or SLM have been found advantageous.

To illustrate an example of an additive manufacturing process, FIG. 16 shows a schematic/block view of an illustrative computerized additive manufacturing system 400 for generating an object 402. In this example, the system 400 is arranged for DMLM, although it should be understood that the general teachings of the disclosure are equally applicable to other forms of additive manufacturing. The AM system 400 generally includes a computerized additive manufacturing (AM) control system 404 and an AM printer 406. The AM system 400 executes code 420 that includes a set of computer-executable instructions defining the object 402 to physically generate the object 402 using the AM printer 406. Each AM process may use different raw materials in the form of, for example, fine-grain powder, liquid (e.g., polymers), sheet, etc., a stock of which may be held in a chamber 410 of the AM printer 406. According to embodiments, the object 402 may be made of a metal or metal compound capable of withstanding the environment of a gas turbine system 10 (FIG. 1). As illustrated, an applicator 412 may create a thin layer of raw material 414 spread out as the blank canvas on a build plate 444 of AM printer 406 from which each successive slice of the final object will be created. In other cases, the applicator 412 may directly apply or print the next layer onto a previous layer as defined by code 420. In the example shown, a laser or electron beam fuses particles for each slice, as defined by code 420. Various parts of the AM printer 406 may move to accommodate the addition of each new layer, e.g., a build platform 418 may lower and/or chamber 410 and/or applicator 412 may rise after each layer.

The AM control system 404 is shown implemented on a computer 430 as computer program code. To this extent, the computer 430 is shown including a memory 432, a processor 434, an input/output (I/O) interface 436, and a bus 438. Further, the computer 430 is shown in communication with an external I/O device/resource 440 and a storage system 442. In general, the processor 434 executes computer program code, such as the AM control system 404, that is stored in memory 432 and/or storage system 442 under instructions from code 420 representative of the object 402.

Additive manufacturing processes begin with a non-transitory computer readable storage medium (e.g., memory 432, storage system 442, etc.) storing code 420 representative of the object 402. For example, the code 420 may include a precisely defined 3D model of the object 402 and can be generated from any of a large variety of well-known computer aided design (CAD) software systems. The AM control system 404 executes the code 420, dividing the object 402 into a series of thin slices that it assembles using the AM printer 406 in successive layers of liquid, powder, sheet or other material.

Various components of a gas turbine system 10 (FIG. 1), or portions of such components, may be produced using an additive manufacturing (AM) process (e.g., using AM system 400, FIG. 16). For example, at least a portion of an exterior wall of a component including an interconnected circuit of cooling channels may be produced via an AM process.

In FIG. 17, for example, a wall coupon 500 for the component 102 depicted in FIGS. 5-10 has been produced (e.g., printed) via an AM process. The wall coupon 500 includes a section 502 of the exterior wall 106 of the component 102. At least a portion of the interconnected circuit 124 of cooling channels 126 is embedded within the wall section 502. The wall coupon 500 further includes a plurality of feed tubes 122 fluidly coupled to the cooling channels 126. To this extent, the wall coupon 500 forms a portion of the independent cooling circuit 100, described above.

According to embodiments, the wall coupon 500 may be produced to any size via an AM process, and may be attached to another section 504 of the component 102 to form at least a portion of the independent cooling circuit 100 (see, e.g., FIG. 18). The section 504 of the component 102 may be formed in a conventional manner (e.g., machined, cast, etc.) or may be formed using an AM process. It should be noted that the wall coupon 500 may configured for use in any of the independent cooling circuits 100, 200, 300 described herein. Attachment may be accomplished, for example, using brazing, welding, or other suitable metal-joining process. FIG. 18 depicts the wall coupon 500 attached (e.g., via brazing/welding) to an impingement plate 114 of the component 102 to form at least a portion of the independent cooling circuit 100. In other embodiments, the entire cooling structure depicted in FIG. 18 may be formed using an AM process, and may be attached to a portion of a component 102 of a gas turbine system 10.

An independent cooling circuit 100 formed using an AM printed wall coupon 500 may be strategically provided in those areas of a component 102 of a gas turbine system 10 that may be subject to spallation. This may be done, for example, without having to produce the entire component 102 using an AM process. Further, an independent cooling circuit 100 formed using an AM printed wall coupon 500 may be retrofittable into an existing component 102 of a gas turbine system 10 to repair areas previously damaged by spallation and/or to selectively provide enhanced cooling to areas of the component 102 subject to spallation as described above.

When producing the independent cooling circuits 100, 200, 300 (or portions thereof) using an AM process, excess powder removal may become a concern. Since the independent cooling circuits 100, 200, 300 do not have a outlet for the cooling fluid 128 (e.g., the circuits are purposefully dead ended), there is no easy way to used forced air to try to remove the excess powder.

According to embodiments, as depicted in FIGS. 19 and 20 and described with reference to the wall coupon 500 produced using an AM process (FIGS. 17 and 18), a plurality of small openings 600 for powder removal may be provided (e.g., formed during the AM process) in the exterior wall section 502 of the wall coupon 500. In FIGS. 19 and 20, for example, the openings 600 are shown extending from the interconnected circuit 124 of cooling channels 126 of the independent cooling circuit 100 through the exterior wall section 502 to the outer surface 132 of the wall coupon 500.

The openings 600 provide an exit that can be used for the removal of excess powder. Powder may be removed, for example, using vibration or by forcing air into the interconnected circuit 124 of cooling channels 126 and out through the openings 600. After powder removal, the openings 600 may be filled/sealed in any suitable manner (e.g., filled with metal, sealant, etc.) to close the independent cooling circuit 100. The openings 600 may be filled/sealed prior to the subsequent application of a TBC coating on the outer surface 132 of the wall coupon 500, or simply sealed by the TBC coating itself. In some cases, a spall event may unblock some of the sealed openings 600 before any of the interconnected circuit 124 of cooling channels 126 are exposed due to the formation of a breach. Cooling fluid 128 may then flow toward and out of the unblocked openings 600 via the independent cooling circuit 100, providing an immediate cooling benefit.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

1. An independent cooling circuit for selectively delivering cooling fluid to a component of a gas turbine system, comprising: an interconnected circuit of cooling channels embedded within an exterior wall of the component; an impingement plate; and a plurality of feed tubes connecting the impingement plate to the exterior wall of the component and fluidly coupling a supply of cooling fluid to the interconnected circuit of cooling channels; wherein the cooling fluid flows through the plurality of feed tubes into the interconnected circuit of cooling channels only in response to a formation of a breach in the exterior wall of the component that exposes at least one of the cooling channels.
 2. The independent cooling circuit according to claim 1, wherein the cooling fluid flows through the interconnected circuit of cooling channels toward the breach in response to the exposure of at least one of the cooling channels.
 3. The independent cooling circuit according to claim 1, wherein the cooling channels are arranged in a grid within the exterior wall of the component, the grid including a plurality of intersections.
 4. The independent cooling circuit according to claim 3, wherein at least some of the cooling channels extend between diagonally adjacent pairs of the plurality of intersections.
 5. The independent cooling circuit according to claim 3, wherein at least some of the cooling channels extend linearly between the plurality of intersections.
 6. The independent cooling circuit according to claim 5, wherein the cooling channels are located at approximately a same distance from an outer surface of the exterior wall of the component.
 7. The independent cooling circuit according to claim 3, wherein at least some of the cooling channels extend non-linearly between the plurality of intersections.
 8. The independent cooling circuit according to claim 7, wherein a distance between the cooling channels and an outer surface of the external wall of the component varies.
 9. The independent cooling circuit according to claim 1, further including a at least one coolant feed channel fluidly coupling the supply of cooling fluid to the plurality of feed tubes.
 10. The independent cooling circuit according to claim 1, further comprising a wall coupon formed using an additive manufacturing process, the wall coupon including a section of the exterior wall of the component and the plurality of feed tubes, wherein the interconnected circuit of cooling channels is embedded within the section of the exterior wall.
 11. The independent cooling circuit according to claim 10, wherein the wall coupon is attached to the impingement plate.
 12. The independent cooling circuit according to claim 10, wherein the wall coupon includes a plurality of powder removal openings extending from the interconnected circuit of cooling channels to an outer surface of the section of the exterior wall.
 13. A cooling system, comprising: a component of a gas turbine system; and an independent cooling circuit for selectively delivering cooling fluid to the component of a gas turbine system, including: an interconnected circuit of cooling channels embedded within an exterior wall of the component; an impingement plate; and a plurality of feed tubes connecting the impingement plate to the exterior wall of the component and fluidly coupling a supply of cooling fluid to the interconnected circuit of cooling channels; wherein the cooling fluid flows through the plurality of feed tubes into the interconnected circuit of cooling channels only in response to a formation of a breach in the exterior wall of the component that exposes at least one of the cooling channels.
 14. The cooling system according to claim 13, wherein the cooling channels are arranged in a grid within the exterior wall of the component, the grid including a plurality of intersections, and wherein the cooling channels extend between the plurality of intersections.
 15. The cooling system according to claim 14, wherein at least some of the cooling channels extend between diagonally adjacent pairs of the plurality of intersections.
 16. The cooling system according to claim 14, wherein at least some of the cooling channels extend linearly between the plurality of intersections, and wherein the cooling channels are located at approximately a same distance from an outer surface of the exterior wall of the component.
 17. The cooling system according to claim 14, wherein at least some the of cooling channels extend non-linearly between the plurality of intersections, and wherein a distance between the plurality of cooling channels and an outer surface of the external wall of the component varies.
 18. A method for reducing spallation-related damage to a component of a gas turbine system, comprising: embedding an interconnected circuit of cooling channels within a section of an external wall of the component; and directing a flow of cooling fluid into the interconnected circuit of cooling channels only in response to a wall breach exposing a portion of the interconnected circuit of cooling channels.
 19. The method according to claim 18, further comprising: forming the section of the external wall including the interconnected circuit of cooling channels using an additive manufacturing process; and replacing a damaged section of the external wall of the component with the section of the external wall including the interconnected circuit of cooling channels.
 20. The method according to claim 18, further comprising: forming the section of the external wall including the interconnected circuit of cooling channels using an additive manufacturing process; and attaching the section of the external wall including the interconnected circuit of cooling channels to the component in an area of the component subject to spallation. 